Molded cartons

ABSTRACT

A molded construction is disclosed that has a cover section hinged to the bottom section with one section having a front wall provided with one or more holes each to receive a locking projection of a portion with which the other section is provided and which is adapted to enter behind the front wall when the carton is closed. The section having the aperture front wall has at least one internal pocket receiving and confining the locking portion of the other section. The locking portion may be a hinged flap and may be connected to the front of the cover section.

United States Patent [56] References Cited UNITED STATES PATENTS 3.215.327 11/1965 Crabtree w i 229/25 3.289.911 12/1966 Boyd et a1. 229/45 3.362.605 1/1968 Bixler 229/25 3.458.108 7/1969 Howarth etal. 229/25 3,506,182 4/1970 Snow et a1. 229/44 R Primary Examiner-Donald F Norton A!I0rneyAbbott Spear ABSTRACT: A molded construction is disclosed that has a coversection hinged to the bottom section with one section having a front wall provided with one or more holes each to receive a locking projection of a portion with which the other section is provided and which is adapted to enter behind the front wall when the carton is closed. The section having the aperture front wall has at least one internal pocket receiving and confining the locking portion of the other section. The locking portion may be a hinged flap and may be connected to the front of the cover section.

PATENTEUNuv 30 I971 SHEET 1 [IF 3 12219222102 Haz' oiol J1Dough@ PATENTEDHBY 30 I971 3, 623.652

SHEET 2 UF 3 12203223021.- Haflow J1. 009715559,

MOLDED CARTONS The present invention relates to molded cartons and to locking means therefor and this application is a continuationin-part of my copending application, Ser. No. 794,l l7, filed Jan. 27, I969 now abandoned.

While cartons in accordance with the invention are adapted for a wide range of other uses, they are herein discussed with particular reference to their use as eg containers as the packaging of eggs presents problems both because they are fragile and because they vary in size and shape.

The molded egg canons that are most widely accepted are of the type in which latching is achieved by providing the bottom section with a locking flap detachably attached to the front wall of the cover section by projections extending through holes in the front wall of the cover section.

The general objective of the present invention is to provide molded cartons in which the latching means may be oppositely arranged, i.e., the hinged cover section has a locking flap having a locking projection which extends outwardly through a hole in the front wall of the bottom section when the cover section is closed with the flap entered within the bottom section. This construction was proposed for egg cartons in the patent to Koppelman US. Pat. No. 2,093,280, dated Sept. I4, 1937, but was not accepted by the egg industry, apparently due to the fact that the locking flap was subjected to the weight of the eggs in the adjacent pockets.

In accordance with the invention this objective is attained by providing the front wall of the bottom section of the carton with an internal pocket below the hole or holes therein to receive and confine the locking portion of the cover section when its projection or projections are caught by the front wall of the bottom section thus to provide support for the front of the cover section from within the carton, the support including shoulders extending lengthwise from the pocket or ockets, and, desirably, particularly when the bottom section is formed with article-receiving cells, offsetting the apertured part of the front wall to prevent any objectionable encroachment of the locking portion into the area of the adjacent cells, and desirably the locking portion is a hinged flap.

Another objective of the invention is to provide guide and backing surfaces for the locking portion, an objective attained by providing that the rear wall of each pocket extends forwardly and downwardly towards the apertured front wall, and that the locking portion has backing projections engageable with the rear walls of the pockets to keep the locking projections in locking position and to brace the apertured front wall against inward movement.

Yet another objective of the invention, where the bottom section is to have article receiving cells, is to have the backing surfaces portions of the transverse partitions of the cells. Preferably such portions merge with the front wall below the lengthwise support thus to make the front wall of the bottom section above the support an easily flexed portion that will yield readily to the camming action of the projections of the locking portion as the carton is closed and to yield as easily on digital engagement to enable that portion of the apertured front wall to be pulled outwardly to disengage it from the projection or projections.

Another objective of the invention, particularly when the locking flap is hinged to the front of the cover section of the carton, is to provide a connection between the apertured portion of the front wall extending across the path of the locking flap and connecting it to internal structure, a central transverse partition, for example, thereby to decrease the flexibility of the apertured wall portion. While this connection increases the security of the interlock between the sections, in the case of egg cartons it results in some difficulty in their being opened if the eggs therein are oversized unless digital engagement is directly above a locking projection. A further objective is, accordingly, to provide a recessed area above each projection thus to facilitate the pulling of the front wall outwardly to disengage it from the projections.

Embodiments of the invention illustrative of these and other of its objectives, novel features, and advantages are shown in the accompanying drawings in which FIG. 1 is a top plan view of a closed egg carton in accordance with the invention;

FIG. 2 is a front elevation thereof;

FIG. 3 is an end view of the carton;

FIG. 4 is a section taken approximately along the indicated lines 4-4 of FIG. 1;

FIG. 5 is a fragmentary view along the same section lines but on a substantial increase in scale;

FIG. 6 is a section taken approximately along the indicated lines 6--6 ofFlG. 1;

FIG. 7 is a fragmentary view along the same section lines but on a substantial increase in scale;

FIG. 8 is a plan view of the opened carton;

FIG. 9 is a front elevation of a closed egg carton in accordance with another embodiment of the invention;

FIG. 10 is a like view thereof but with the cover partly open;

FIG. 11 is a section, on a substantial increase in scale, taken approximately along the indicated lines 1l-l1 of FIG. 9; and

FIG. 12 is a section, on the scale of FIG. 1], taken approximately along the indicated lines I2 12 thereof.

The egg carton illustrated by FIGS. l-8 is molded from pulp or a suitable plastic of which polystyrene foam is a preferred example, to provide a bottom section, a cover section, and a locking flap indicated generally at 10, 11, and 12, respectively.

The bottom section 10 is shown as of the type having two series of egg-receiving cells 13 with each series having six such cells. The cells 13 are integrally connected above their bottom ends with the connecting structure defining lengthwise and transverse ribs 14 and 15, respectively, a series of posts 16 into which the ribs merge and marginal, stiffening flanges 17 providing a rectangular seat for the cover section 11 when it is closed. While the rear and end walls of the bottom section 10 include the outer surfaces of the appropriate egg cells 13, its front wall, in accordance with the invention, also has a flat faced, upwardly and outwardly inclined portion 18 shown as terminating close to but short of the ends of the bottom section, and outwardly offset by a lengthwise shoulder 19 and end shoulders 20.

The front wall portion 18 has transversely spaced holes 21 and the transverse ribs 15 incline downwardly and outwardly as at 15A and merge with the lengthwise shoulder 19 thus to establish a series of V-shaped pockets generally indicated at 22, see FIGS. 4 and 5.

The cover section 11 has a top wall 23 and outwardly and downwardly inclined front, rear, and end walls indicated at 24, 25, and 26, respectively, terminating in a marginal, outwardly disposed shoulder 27 for engagement with the flange 17. It is preferred that both the flange l7 and the shoulder 27 at the ends of the bottom section 10 and the cover section 11 be centrally recessed as at 17A and 27A to ensure carton ventilation.

The flange l7 and the shoulder 27 at the rear of the bottom and cover sections are integrally connected by a hinge 28 and the locking flap 12 is integrally connected to the shoulder 27 at the front of the cover section 11 by a hinge 29. The hinges 28 and 29 are conventional, the hinge 28 permitting the cover section to be swung through an arc in the neighborhood of I and the hinge 29 shown in the drawings binding when the flap is swung into a position in which it will enter and have sliding contact with the inner surface of the wall portion 18.

The locking flap 12, as may best be seen in FIGS. 5-8, has a relatively narrow hinge section 12A providing a shoulder engageable with the flange 17 and a relatively wide main section 12B disposed at an angle relative thereto and provided with a pair of longitudinally spaced locking projections 30 and a series of oppositely disposed backing projections 31. The locking projections 30 are outwardly disposed when the locking flap 12 is within the carton and are dimensioned and spaced for entry through the holes 21 when the cover section 11 is in its closed position. The holes 21 are dimensioned to pennit the free edge of the flap 12, when locked to the wall portion 18, to butt against the lengthwise shoulder 19. There is one backing projection 31 shown for each transverse rib 15 and the projections 31 are shaped so that their walls 31A are parallel and engageable with the rib portions 15A.

It will be noted, as may best be seen in F [08. 5 and 7, that each projection 30 is of a shape such that its lower portion, as the flap 12 is entered in the bottom section 10, functions as a cam while its upper portion functions as a hook. It will be appreciated that when the flap 12 is swung relative to the front wall 24 of the cover section from its position shown in FIG. 8 the position in which the cartons are molded, into its bottom entering position, the hinge 29 has reached its limit. The flap 12 thus becomes a supporting part of the front wall 24 as long as it is held against swinging outwardly into its original position towards which it is resiliently urged when the flap 12 is disposed for entry into the bottom section 10. In addition, the portions 15A also function as guide surfaces engageable by the free end of the flap 12 as it enters the carton bottom 10.

As the wall portion 18 is not directly tied to the pocketforming structure, it yields readily to the camming action of the projections until they hook through the holes 21 and this same yieldability of the wall portion 18 enables the carton to be easily opened by pulling the upper edge of the wall portion 18 outwardly sufficiently to free it from the projections 30. To this end the central portion of the flange structure 17 is recessed as at 178 to facilitate digital releasing engagement therewith.

The cover 11 is shown as having a pair of aligned, hollow ribs 32 extending lengthwise and centrally thereof, the ribs 32 being spaced from each other and from the ends of the cover. The ribs 32 are dimensioned to engage the posts 16 when the cover is closed and, desirably, the ribs 32 are sufficiently narrow to avoid encroachment into the space occupied by eggs in the cells 13 and also for that reason, their bottom edges are recessed as at 32A between the posts.

As the embodiment of the invention illustrated by FIGS.

-12 is generally similar to that just described, it will not accordingly be described except as to its different features and corresponding parts are distinguished by the prefix addition 1 to the appropriate reference numerals.

It will be noted that the central transverse rib 33 differs from the other transverse ribs 115 in that it extends to and joins the front wall 118 close to but slightly below the upper edge thereof and thus divides the lengthwise shoulder 119, fonning a notch 34 in the front wall and requiring a corresponding notch 35 in the flap 112. This construction materially increases the resiliency of the front wall 118 and while onsuring that the carton will not accidentally open, the increased wall stiffness makes it difficult to open full cartons if the eggs in the proximate cells are slightly oversize because such eggs press the locking fiap 1 l2 outwardly to a slight extent. For that reason, if the user inserts the tip of a finger in back of the front wall 118 at any place other than directly above an interlock, it is difficult to pull it outwardly to an extent sufficient to free it.

For that reason, the front wall 118 is recessed as at 1178 directly above each hole 121 to provide a finger grip and it will be noted that the shoulder 112A extending along the flap ll2 adjacent the hinge 129 is interrupted as at 36 above each projection 130 thus to facilitate digital entry into the finger grip 1173 and release of the interlock between the carton sections.

1 claim:

1. A molded carton comprising a bottom section, a cover section, hinge means integrally joining the rear edges of said sections, one section including a front wall having at least one hole therein, the other section including a portion extending from its front to enter behind the front wall as the cover section is swung into its carton closing position, said portion including at least one locking projection disposed and dimensioned to enter said hole when said carton is closed, and said one section including at least one internal pocket disposed in the path of said portion as the carton is closed and dimensioned then to confine said portion against movement rearwardly with respect to said front wall.

2. The molded carton of claim 1 in which the portion including the locking projection is a hinged locking flap.

3. The molded carton of claim 2 in which a shoulder extends lengthwise of the interior of the front wall on each side of the pocket and offsets a corresponding portion of the front wall by the thickness of the lockin flap.

4. The molded carton 0 claim 1 in which the pocket is substantially V-shaped and the portion including the locking projection also includes a backing part shaped and dimensioned to fit the pocket.

5. The molded carton of claim I and a shoulder extending lengthwise of the interior of the front wall on each side of the pocket engageable by the free edge of said portion.

6. The molded carton of claim 1 in which the section having the pocket also includes at least one transverse ridge joining the front wall and defining the rear wall of the pocket.

7. The molded carton of claim I in which the portion including the locking projection is a hinged locking flap, each pocket is V-shaped and the locking flap also includes backing portions each shaped and dimensioned to fit a pocket.

8. A molded carton comprising a bottom section, a cover section, both sections including front, rear, and end walls, hinge means integrally joining said rear walls, the bottom section including transverse walls defining therewith a plurality of article receiving cells, the front wall of one section having at least one hole, the front wall of the other section including a portion disposed to enter behind the front wall of said one section as the cover section is swung into its carton closing position, said portion including a locking projection for each hole disposed and dimensioned to enter therein when the carton is closed, and said one section including at least one internal pocket disposed in the path of said portion as the carton is closed and dimensioned them to confine said portion against movement rearwardly with respect to said front wall.

9. The molded carton of claim 8 in which said one section is the bottom section.

10. The molded carton of claim 9 in which at least some of the transverse components of the cell defining structure include downwardly inclined ends joining the front wall above bottom and below the hole and defining with the upper part of front wall a series of said pockets.

11. The molded carton of claim 9 in which the portion including the locking projection is a hinged locking fiap and the front wall of the bottom has a shoulder extending lengthwise of its interior along the front of each cell and so offsetting the upper part of the front wall as to accommodate the flap without its encroachment into the pockets.

12. The molded carton of claim 11 in which one of the transverse components of the cell defining structure joins the upper part of the front wall to stifien it and the flap has a notch disposed and dimensioned to accommodate said one trans verse component.

13. The molded carton of claim 11 in which the pockets are substantially V-shaped and the locking flap also has backing portions, each shaped to fit a pocket.

14. The egg carton of claim 13 in which each hole is in front of a cell and the upper edge of the front wall of the carton has a recess directly above each hole therein and providing a finger grip.

15. The egg carton of claim 13 in which the upper edge of the front wall includes an outwardly disposed shoulder having a recess for each hole in the front wall and directly above it and providing a finger grip, and the flap has lengthwise shoulder portions marginally of its hinge connection with the front wall of the cover section, the flap shoulder overlying the front wall shoulder when the carton is closed, there being a space between said shoulder portions above each projection facilitating access to the subjacent finger grip.

16. The molded carton of claim 15 in which each pocket is V-shaped and the locking flap also includes backing portions each shaped and dimensioned to fit a pocket. 

1. A molded carton comprising a bottom section, a cover section, hinge means integrally joining the rear edges of said sections, one section including a front wall having at least one hole therein, the other section including a portion extending from its front to enter behind the front wall as the cover section is swung into its carton closing position, said portion including at least one locking projection disposed and dimensioned to enter said hole when said carton is closed, and said one section including at least one internal pocket disposed in the path of said portion as the carton is closed and dimensioned then to confine said portion against movement rearwardly with respect to said front wall.
 2. The molded carton of claim 1 in which the portion including the locking projection is a hinged locking flap.
 3. The molded carton of claim 2 in which a shoulder extends lengthwise of the interior of the front wall on each side of the pocket and offsets a corresponding portion of the front wall by the thickness of the locking flap.
 4. The molded carton of claim 1 in which the pocket is substantially V-shaped and the portion including the locking projection also includes a backing part shaped and dimensioned to fit the pocket.
 5. The molded carton of claim 1 and a shoulder extending lengthwise of the interior of the front wall on each side of the pocket engageable by the free edge of said portion.
 6. The molded carton of claim 1 in which the section having the pocket also includes at least one transverse ridge joining the front wall and defining the rear wall of the pocket.
 7. The molded carton of claim 1 in which the portion including the locking projection is a hinged locking flap, each pocket is V-shaped and the locking flap also includes backing portions each shaped and dimensioned to fit a pocket.
 8. A molded carton comprising a bottom section, a cover section, both sections including front, rear, and end walls, hinge means integrally joining said rear walls, the bottom section including transverse walls defining therewith a plurality of article receiving cells, the front wall of one section having at least one hole, the front wall of the other section including a portion disposed to enter behind the front wall of said one section as the cover section is swung into its carton closing position, said portion including a locking projection for each hole disposed and dimensioned to enter therein when the carton is closed, and said one section including at least one internal pocket disposed in the path of said portion as the carton is closed and dimensioned then to confine said portion against movement rearwardly with respect to said front wall.
 9. The molded carton of claim 8 in which said oNe section is the bottom section.
 10. The molded carton of claim 9 in which at least some of the transverse components of the cell defining structure include downwardly inclined ends joining the front wall above its bottom and below the hole and defining with the upper part of front wall a series of said pockets.
 11. The molded carton of claim 9 in which the portion including the locking projection is a hinged locking flap and the front wall of the bottom has a shoulder extending lengthwise of its interior along the front of each cell and so offsetting the upper part of the front wall as to accommodate the flap without its encroachment into the pockets.
 12. The molded carton of claim 11 in which one of the transverse components of the cell defining structure joins the upper part of the front wall to stiffen it and the flap has a notch disposed and dimensioned to accommodate said one transverse component.
 13. The molded carton of claim 11 in which the pockets are substantially V-shaped and the locking flap also has backing portions, each shaped to fit a pocket.
 14. The egg carton of claim 13 in which each hole is in front of a cell and the upper edge of the front wall of the carton has a recess directly above each hole therein and providing a finger grip.
 15. The egg carton of claim 13 in which the upper edge of the front wall includes an outwardly disposed shoulder having a recess for each hole in the front wall and directly above it and providing a finger grip, and the flap has lengthwise shoulder portions marginally of its hinge connection with the front wall of the cover section, the flap shoulder overlying the front wall shoulder when the carton is closed, there being a space between said shoulder portions above each projection facilitating access to the subjacent finger grip.
 16. The molded carton of claim 15 in which each pocket is V-shaped and the locking flap also includes backing portions each shaped and dimensioned to fit a pocket. 